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Views: 266 Author: Dongguan Hemax New Energy Publish Time: 2026-11-12 Origin: Dongguan Hemax New Energy
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● What Can Be Customized in a Lithium Battery Pack? A Quick Overview
● 1. Cell Chemistry, Format, and Supply Strategy
>> Chemistry should match the application
>> Cell format affects more than appearance
● 2. Voltage, Capacity, and Real-World Power Output
>> Customize the full operating voltage range
>> Specify continuous and peak current separately
>> Estimate runtime using usable energy
● 3. Dimensions, Enclosures, and Installation Interfaces
● 4. Battery Management and Communication
>> Customize protection around validated limits
>> Define the communication protocol, not just the connector
● 5. Charging and Thermal Management
● 6. Connectors, Serviceability, and Branding
● 7. Testing, Documentation, and Compliance Planning
>> Transport testing is not product certification
>> Select standards according to the actual product
● 8. Three Application Examples That Reveal Hidden Requirements
>> Stair-climbing equipment: investigate transient loads
>> Logistics AGVs: evaluate charging within the working day
>> Drones: compare usable performance, not capacity alone
● 9. How to Prepare a Custom Battery Pack RFQ
● Frequently Asked Questions About Custom Lithium Battery Packs
>> Can I customize voltage and capacity independently?
>> Can a custom battery fit an existing compartment?
>> Can I request CAN communication?
>> Are custom lithium battery packs automatically waterproof?
>> Do certified cells make the complete pack certified?
>> How long does OEM/ODM battery development take?
● Start Your Custom Battery Project with Dongguan Hemax
At Dongguan Hemax New Energy Co., Ltd., we focus on customized OEM/ODM lithium battery solutions for stair-climbing machines, logistics AGVs, drones, robots, energy storage systems, mobility products, smart homes, medical devices, and industrial equipment.
What can be customized in a lithium battery pack? The answer extends beyond voltage and capacity. Customization can include cell selection, electrical configuration, dimensions, enclosure design, battery management, communication, charging, thermal control, connectors, labeling, and validation requirements.
Our perspective is straightforward: a battery should be designed around how the equipment actually works. A pack that fits the compartment but cannot handle startup current, charging conditions, or communication requirements is not a complete solution.
This guide explains the main customization options, the engineering trade-offs behind them, and the information buyers should prepare before requesting a quotation.
A custom lithium battery pack combines interconnected design decisions. Changing one parameter often affects several others.
| Customization area | Typical options | Main design consideration |
|---|---|---|
| Cell selection | Chemistry, format, capacity, supplier | Energy, power, lifetime, availability |
| Electrical configuration | Series and parallel connections | Voltage range and usable energy |
| Power output | Continuous and peak discharge | Load profile and heat generation |
| Mechanical design | Shape, dimensions, mounting, housing | Installation and environmental exposure |
| Battery management | Protection, balancing, monitoring | Safety and system compatibility |
| Communication | CAN, SMBus, UART, other interfaces | Protocol and host integration |
| Charging | Charge limits, interfaces, control | Cell requirements and charging time |
| Validation | Electrical, mechanical, environmental tests | Application and destination market |
The best starting point is not a preferred battery model. It is a documented operating requirement.
Cell selection establishes the foundation of custom lithium battery pack design.
Lithium iron phosphate, commonly called LiFePO4 or LFP, and nickel-manganese-cobalt chemistries, commonly called NMC, offer different performance trade-offs. Selection should use the proposed cell's actual specifications rather than chemistry labels alone.
For a drone, weight and power delivery may dominate. For an AGV, operating duty, charging opportunities, service life, and maintenance may deserve greater attention.
No chemistry is automatically best for every application.
Cylindrical, prismatic, and pouch cells create different opportunities for packaging, support, interconnection, and thermal design.
An unusual enclosure does not necessarily require a custom-manufactured cell. A practical design may arrange existing cells into modules that fit the available space.
Buyers should also discuss approved alternatives and change control. Replacing a cell later can require electrical, mechanical, thermal, and compliance reassessment.
Voltage and ampere-hours are useful specifications, but they do not fully describe battery performance.
Series connections increase pack voltage. Parallel connections increase capacity and can increase current capability when the design supports appropriate current sharing.
Equipment compatibility must cover:
- Maximum fully charged voltage.
- Nominal operating voltage.
- Minimum permitted discharge voltage.
- Voltage drop under heavy load.
- Charger and controller limits.
Two packs described as "48 V" may not share the same charging voltage or usable operating range.
A stair-climbing machine may demand brief high-current events. A robot may draw sustained current while also experiencing acceleration peaks.
A useful specification states continuous current, peak current, peak duration, repetition rate, and ambient temperature.
The entire current path must support that requirement: cells, interconnects, wiring, connectors, protective components, and switching devices.
Consider an illustrative device consuming an average of 200 W for four hours. Its load requires approximately 800 Wh.
The selected pack needs additional allowance for conversion losses, operating limits, temperature effects, and capacity loss over service life. The appropriate margin depends on the application.
This is why runtime promises should follow a defined load profile, not a capacity label alone.
Mechanical customization determines whether the battery integrates reliably into the equipment.
Options may include:
- Overall dimensions and internal layout.
- Mounting brackets and attachment points.
- Cable exit position and connector orientation.
- Removable handles or locking mechanisms.
- Housing material and protective features.
- Access for inspection or replacement.
A compact enclosure is useful only if it preserves insulation, clearances, structural support, and thermal performance.
For outdoor or dusty equipment, define the required ingress-protection target and test conditions. A sealed appearance does not demonstrate a verified protection rating.
*Suggested visual: An exploded battery-pack illustration showing cells, insulation, BMS, interconnects, enclosure, and mounting points.*
The battery management system, or BMS, links cell-level monitoring with equipment-level operation.
Depending on the architecture, BMS functions may include:
- Cell-voltage and temperature monitoring.
- Overcharge and overdischarge protection.
- Overcurrent and short-circuit protection.
- Cell balancing.
- State-of-charge estimation.
- Fault recording and charge control.
Protection thresholds must remain consistent with cell specifications and the validated pack design. Raising a current limit without reviewing the hardware is not a safe performance upgrade.
"CAN communication required" is incomplete.
A usable specification also defines message identifiers, data scaling, update intervals, fault codes, startup behavior, timeout handling, and recovery behavior.
Similarly, a state-of-charge display needs validation under representative conditions. Its usefulness depends on the estimation method, calibration, operating profile, and cell behavior.
For robotics and AGVs, communication should help the host respond appropriately to warnings—not merely display battery percentage.
Charging requirements should be agreed alongside discharge requirements.
Customization may cover charging current, charge-enable signals, separate charging ports, docking contacts, charger communication, and temperature-dependent limits.
Faster charging is constrained by the cells, electrical path, thermal design, and operating environment. A higher-power charger does not independently make a pack fast-charge capable.
Temperature requirements also need precision. Storage, charging, and discharging limits are different specifications.
Thermal options may include conductive paths, cooling interfaces, ventilation, insulation, or controlled heating where justified. These measures must be evaluated as part of the complete system.
For equipment with regenerative braking, engineers should also assess whether the battery can accept returned energy at relevant temperatures and states of charge.
Smaller integration details can determine installation quality and long-term usability.
Electrical customization may include cable length, conductor size, terminal style, polarity protection, signal connections, and connector retention.
Serviceability requirements may include:
- Accessible identification labels.
- Replaceable external components where appropriate.
- Diagnostic access.
- Defined removal procedures.
- Clear handling instructions.
Branding can include logos, model identifiers, serial numbers, barcodes, and equipment-specific labeling.
However, labels must accurately describe the supplied configuration. Certification marks and performance claims require appropriate evidence and authorization.
In our view, a useful OEM/ODM battery solution should be understandable to the installer, operator, and service technician—not only to the design engineer.
Compliance should influence the design brief before the enclosure and electronics are finalized.
UN 38.3 addresses lithium-cell and battery transport testing. It does not replace application-specific safety evaluation or finished-equipment requirements.
The applicable test summary should correspond to the relevant battery design. Certified or tested cells do not automatically establish compliance for every assembled pack.
Potentially relevant standards include IEC 62133-2 for portable lithium systems, IEC 62619 for industrial lithium batteries, and UL 1973 for specified stationary and motive auxiliary applications.
These are not interchangeable approvals. Applicability depends on the product, intended use, market, and certification scheme.
Medical equipment and energy storage systems may also involve requirements beyond the battery itself.
Buyers should request a clear document list covering specifications, drawings, test evidence, operating instructions, and applicable transport documentation.
The following are illustrative engineering scenarios, not claims about completed Hemax projects.
A pack may support average motor demand but struggle during a loaded stair transition.
The design review should examine current peaks, voltage sag, connector heating, and protection behavior under representative loads.
An AGV may recharge during short docking periods rather than through one long charging session.
Battery sizing should therefore consider route duration, charging windows, docking reliability, communication, and lifetime energy throughput.
Adding capacity also adds weight. That additional mass can change flight power demand.
The useful comparison is system-level flight performance under defined payload, temperature, and operating conditions—not simply the largest available ampere-hour rating.
A well-prepared request for quotation reduces assumptions and makes supplier proposals easier to compare.
Provide:
1. Equipment type and intended operating environment.
2. Required voltage range and average power consumption.
3. Continuous current, peak current, and peak duration.
4. Target runtime and charging schedule.
5. Available dimensions, weight limit, and mounting drawings.
6. Charger specifications and communication requirements.
7. Charging, discharge, and storage temperatures.
8. Target markets and known compliance requirements.
9. Expected production volume and launch schedule.
10. Required documentation, labeling, and service strategy.
Then define measurable acceptance criteria.
For example, replace "long runtime" with a runtime target under a specified load and temperature. Replace "high current" with a current-duration profile.
Our recommended principle is simple: agree on how success will be measured before comparing sample prices.
Within practical limits. Series and parallel arrangements provide flexibility, but available cells, space, weight, current requirements, and charging compatibility constrain the final combination.
Often, but drawings and tolerances are essential. The review must also allow for connectors, mounting, insulation, installation access, and thermal requirements.
Yes, where supported by the selected architecture. Specify the complete protocol and operating behavior, not only CAN hardware or connector pin assignments.
No. Define an ingress-protection target and verify the assembled design under appropriate testing. Housing materials alone do not establish protection performance.
No. Pack construction, protection, wiring, enclosure, and intended use can introduce additional evaluation requirements.
There is no reliable universal timeline. Existing platforms may reduce development work, while new electronics, tooling, firmware, or testing can extend the schedule. Request separate milestones for design, samples, validation, and production release.
The most valuable customization is not the longest options list. It is the combination that meets your equipment's operating requirements with a clear validation plan.
Contact Dongguan Hemax New Energy Co., Ltd. with your application, voltage range, load profile, installation drawing, and target market. Request an OEM/ODM feasibility review covering electrical design, mechanical integration, communication, charging, and documentation before finalizing the battery specification.
1. Company information supplied by the client. Dongguan Hemax New Energy Co., Ltd. company introduction. Source for the company's stated OEM/ODM focus and application areas. No customer reviews, certificates, or project records were supplied.
2. Lithion Battery. "Custom Battery Pack Design: Requirements to Production." Engineering background on cell selection, electrical architecture, BMS, thermal management, validation, and development planning. [lithionbattery]
3. U.S. Pipeline and Hazardous Materials Safety Administration. "Lithium Battery Test Summaries." Authoritative guidance on lithium battery transport testing and test-summary requirements. [phmsa.dot]
4. International Air Transport Association. "Battery Guidance Document." Guidance on lithium battery transport requirements and the availability of UN 38.3 test summaries. Shipment-specific requirements should be checked against the applicable current rules. [iata]
5. UL Solutions. "Battery Safety Testing and Certification." Background on battery safety evaluation and the scope of portable lithium-system standards, including IEC 62133-2. [ul]
6. UL Solutions. "Battery Module and Pack Testing for Manufacturers." Background on pack-level evaluation and application-specific standards, including UL 1973. [ul]
7. UL Solutions. "Your Guide to Battery Energy Storage Regulatory Compliance." Background on the relationship between industrial battery requirements, IEC 62619, and energy storage compliance. [ul]
8. Intertek. "UN 38.3 Testing for Lithium Batteries." Additional context on test summaries and battery design considerations relevant to transport evaluation. [intertek]
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